Optimization of Redundancy Allocation With Green Components and Applications in Automotive Systems

ABSTRACT

Traditional reliability evaluation in redundancy allocation problems often overlooks the early‐stage low‐failure‐probability region, leading to potential inconsistencies in modeling component behavior. To address this issue, this study proposes a novel Green Reliability Redundancy Allocation Problem (Green‐RRAP) framework based on the Green Design Method (GDM). The proposed approach incorporates a safety‐period‐based reliability model, in which a probability threshold is used to characterize delayed degradation behavior under an exponential time‐to‐failure assumption. By integrating this formulation into redundancy allocation, the proposed model enables more realistic reliability evaluation while maintaining analytical tractability. The effectiveness of the approach is validated through benchmark problems and a real‐world automotive control system. The results demonstrate that the proposed method improves system reliability while reducing cost and response time compared to existing approaches, and achieves efficient configurations with fewer redundant components. These findings highlight the potential of incorporating safety‐period‐based reliability modeling into RRAP and provide a practical framework for reliability optimization in complex engineering systems.